Self service key duplicating machine with automatic key model identification system

ABSTRACT

An automatic key duplicating machine is disclosed. A master key identification module includes at least one key blade cross-section detector with a plurality of sliding elements, the master key identification module being configured to determine a key type for a master key based at least in part on engagement of the plurality of sliding elements with a blade profile of the master key. A key extraction module is configured to retrieve a key blank of an identified key type. A key cutting module is configured to cut the key blank in accordance with a tooth pattern of the master key.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of U.S. patent application Ser. No. 14/920,060,filed Oct. 22, 2015, which is a continuation of Ser. No. 13/622,036,filed Sep. 18, 2012, now U.S. Pat. No. 9,199,318, which is a division ofSer. No. 11/998,101, filed Nov. 28, 2007, now U.S. Pat. No. 8,287,215,which claims priority from U.S. Provisional Application No. 60/867,796,filed Nov. 30, 2006, and from U.S. Provisional Application No.60/867,403, filed Nov. 28, 2006. All of the above applications arehereby incorporated herein by reference.

TECHNICAL FIELD

This is directed to the field of key duplication. More specifically,this is directed to the field of apparatuses and methods of automatickey duplication involving as little trained human operator input aspossible.

BACKGROUND

Duplicate keys are typically cut from pre-existing master keys using ahand-operated table-top tool having two clamps, a cutting wheel, afollower and a cleaning wheel. A schematic of such a conventional keycutting tool appears in FIG. 1. In operation, a locksmith or someone ofat least some training on the machine examines the master key A, triesto determine what type of key it is by eye/tool, tries then to determinewhich model of key it is by eye, and selects a corresponding key blank Bfrom an array of scores of different models. The master key A is thenclamped at the following station C, and the key blank B is clamped atthe cutting station D. The two stations C and D are attached to a commonbase E, which is opposite the follower F and cutter G (which are bothtogether mounted on base H).

Base H is then pressed down towards base E, or, conversely, base E ismoved up towards base H, depending on the machine model, in thedirection of arrow Y. This causes the cutter G to be brought intocontact with the key blank B. The keys are moved longitudinally in thedirection of arrow X with respect to the follower F and cutter G. Sincethe key blank B and the master key A are mechanically linked (i.e., theyare clamped to the same base E), the follower F rides along the toothpattern of the master key A, and the cutter G simultaneously cuts intothe blank blade of the key blank B, removing blade material in the sameconfiguration as the tooth pattern of the master key A. When the cuttingis done, the operator removes both keys and places the newly cut keyunder a rotating cleaning wheel or brush (not shown) to remove burrs andany stray material left over from the cutting process.

This process is fraught with potential problems and mistakes. First, theoperator may select the wrong type of key blank. Since each type of key(e.g., Kwikset, Schlage, Segal, etc.) has a differently shapedcross-sectional profile, using the wrong type will result a key thatwill not be able to enter the lock properly. Second, the operator mayselect the right type of key but the wrong model. Keys of the same typecome in different lengths, for example, and the operator may select ablank having the wrong length. Moreover, there are many models of keyscurrently on the market. Many of the models are very similar in shapeand cross-section. Even to the trained professional, modelidentification can be quite difficult and erroneous. This problem isonly made worse by the tens of aftermarket manufacturers that producekeys with models that are designed to have the same dimensionalfeatures, but are actually manufactured with differences. Key modelidentification is necessary before duplication of a key. Third, theoperator may not properly align the master key in clamp C, therebycausing the two keys to be out of register and he may not align theblank properly. Fourth, the operator may apply too little pressure orinconsistent pressure on base E and cause key B to be cut too shallowlyor incompletely. Other problems may arise. In addition, since the devicemust be operated by someone trained on the device, duplicate keys maynot always be readily available. Conventional key cutting machines areusually located in locksmith shops and hardware stores, or similaravenues of commerce not typically known to be open late into theevening. For these and other reasons, there is a long felt need toautomate the process of key duplication so that ordinary consumers canobtain accurate duplicate keys by themselves, without requiring aspecialty shop to be open for business, and without requiring a skilledtradesperson on hand to operate the machine.

Several attempts to automate the process of key duplication have beenpartly successful at best. There are several patents to so-called“automated” key identifying and/or duplicating devices, such as U.S.Pat. Nos. 4,899,391 and 5,127,532 to Cimino; U.S. Pat. No. 5,351,409 toHeredia; U.S. Pat. No. 3,956,968 to Crasnianski; and U.S. Pat. No.5,538,374 to Cole et al. However, in each of these and others like them,one or more of the steps required to duplicate a key are still manual.For example, in some devices and methods, the operator must stilldetermine what type of key the master key is and select a correspondingkey blank. In other (and/or the same) devices, the master key is stillaligned by hand and clamped by hand. Many of these prior devices stillrequire a skilled tradesman to operate the machinery. In fact, even inthe most automated key machine of today, the following steps are stillperformed by the operator: insertion of customer/master key, partialalignment of customer/master key, clamping of customer key,identification of customer key model, retrieval of key blank, insertionof key blank, partial alignment of key blank, clamping of key blank,starting machine, unclamping of customer key, removal of customer key,unclamping of key blank, removal of key blank, de-burring of key blank,returning customer key to customer, giving new key to customer andcharging the customer a fee for the service.

Thus, there is still a long-felt need for a fully automatic keyidentifying and/or duplicating machine that can be operated by anordinary consumer in a manner as easy as purchasing an item from avending machine or receiving money from an automated teller machine.

SUMMARY

The invention fulfills the above and other long felt needs. In oneembodiment, a master key clamping module receives and secures a masterkey having a tooth pattern to be duplicated and a master key alignmentmodule is movably disposed into and out of proximity with the master keyclamping module. The master key is aligned by the alignment modulewithin the master key clamping module. A master key identificationmodule is disposed in fixed relation to the master key clamping moduleand identifies a type of key secured in the master key clamping module.A key cutting module is provided including a key blank cutter. A centralpositioning base is automatically movable into and out of engagementwith the master key alignment module and alternately automaticallymovable into and out of engagement with the key cutting module. Thecentral positioning base is adapted to move the master key alignmentmodule into proximity with the master key clamping module and adapted tosecure a key blank to be cut at the key cutting module in accordancewith the tooth pattern of a clamped master key.

Preferably, at least one magazine is provided for housing a plurality ofkey blanks; the central positioning base is movable into and out ofproximity with the magazine and is adapted to cause removal one of thekey blanks from the at least one magazine and move the removed key blankto the key cutting module. The central positioning base preferablyincludes a key blank securing groove and a key blank clamp on at leastone side of the key blank securing groove adapted to secure a key blankinserted into the key blank securing groove. Preferably, a plurality ofthe magazines are provided, each of the magazines adapted to house adifferent model or color of the key blanks.

A key extraction module is provided engageable with the centralpositioning base substantially adjacent the key blank securing grooveand slidingly disposed along the plurality of magazines and movable to aselectable one of the magazines by the central positioning base. The keyextraction module preferably includes a reciprocatable push rod,disposable behind a lowermost key blank housed in one of the magazines,adapted to push the lowermost key blank out of the magazine. A guideroller is disposable adjacent the key blank being pushed out of themagazine by the push rod, substantially opposite the key blank securinggroove of the central positioning base when the central positioning baseengages the key extraction module. The guide roller preferably includesa circumferential guide groove receiving the key blank being pushed outof the magazine.

The extraction module preferably further includes an extraction basesupporting the push rod and the guide roller and a cam rider projectingfrom and mechanically linked to the push rod. A key support arm ishingedly attached to the extraction base and cammingly connected to thepush rod via the cam rider, the key support arm having a blade supportplatform at a distal end, the key support arm being spring-biased upwardtowards the push rod. When a key blank is being removed from one of themagazines, the key support arm is biased upward to cause contact betweenthe blade support platform and the blade of the emerging key blank. Thekey support arm preferably further includes a proximal raised cammingsurface, a distal raised camming surface, and a central lowered cammingsurface. When the cam rider rides over either of the proximal or distalcamming surfaces, the cam rider pushes the key support arm down awayfrom the emerging key blank to prevent contact between the emerging keyblank head and the blade support platform.

Each of the key blank magazines preferably further includes a pair ofsubstantially parallel leaf springs disposed at one end of the magazine,the leaf springs being spaced apart to guide a lowermost key blank inthe magazine out of the magazine during extraction, and generally toavoid the bottom keys from being knocked out/coming out by accident.

The master key alignment module preferably includes an alignment head,spring mounted on a reciprocating shaft, preferably in a distalposition, the head being engageable with the master key as the masterkey is being inserted into the master key clamping module when themaster key alignment module is in proximity to the master key clampingmodule. A locking switch is preferably provided engageable with thereciprocating shaft; when the locking switch engages the reciprocatingshaft, the shaft is pushed with greater force and locked in the distalposition. The locking switch preferably includes a rotating lockinglever engageable with the reciprocating shaft by movement of the centralpositioning base against the locking lever in a direction substantiallyperpendicular to a sliding direction of the master key alignment module.The master key alignment module preferably further includes a master keyshoulder detecting switch. When the master key is fully inserted intothe master key clamping module, a shoulder of the inserted master keyabuts against the master key shoulder detecting switch. The alignmenthead preferably includes a sloped leading surface and more preferably agroove adapted to accommodate and lead a master key as the master key isbeing inserted into the master key clamping module.

The master key clamping module preferably includes guideway projectionsthat receive and guide a master key being inserted into the master keyclamping module as well as an open section exposing teeth of theinserted master key.

The master key identification module includes a blade length sensingelement spring-biasedly disposed within the master key clamping moduleand abuttable against a distal end of a master key inserted into theclamping module. At least one blade cross-section detector is alsoprovided laterally engageable with the blade of the inserted master key,the cross-section detector having a profile corresponding to across-sectional profile of a given type of key. When the bladecross-section detector engages a key of the type corresponding to theprofile, the profile substantially engages the blade and the master keyis determined to be of the given key type. When a key type match isdetermined and the blade length sensing element determines the length ofthe inserted master key, the master key is determined to be a specifickey model. The blade cross-section detector includes at least one pairof sliding elements disposed within the clamping module on oppositesides of the inserted master key, each of the sliding elements having aprofile. When the sliding elements engage a key of the typecorresponding to its profile, the sliding elements substantially closearound the master key blade, and when the sliding elements engage a keynot of the type corresponding to the profile, the sliding elements donot close around the master key blade or close too far around the masterkey blade.

A plurality of the pairs of the sliding elements are preferablyprovided. Each of the pairs of the sliding elements preferably havedifferent respective profiles each corresponding to different types ofkeys.

The key cutting module preferably further includes a cut key cleaner,such as, for example, a rotating cleaning wheel; the key blank cuttermay be, for example, a rotating cutting wheel. A first enclosure isprovided substantially but not entirely surrounding the key blankcutter, the first enclosure having a first window exposing a portion ofthe key blank cutter for cutting. A second enclosure is providedsubstantially but not entirely surrounding the cut key cleaner, thesecond enclosure having a second window exposing a portion of the cutkey cleaner for cleaning. A vacuum source is in communication with thefirst and second enclosures that creates negative pressure substantiallyaround the key blank cutter and the cut key cleaner to substantiallyremove debris created during cutting and cleaning of a key blank.Flexible flaps are preferably disposed on proximal and distal sides ofthe first and second windows (and more preferably, also on the top andbottom of the windows), engageable with the central positioning basewhen the central positioning base is securing a key blank at the keycutting module. The flaps on the distal sides of the windows arepreferably longer than the flaps on the proximal sides of the windows.The key blank cutter preferably includes a cutting wheel rotatable in afirst direction, and the cut key cleaner includes a cleaning wheelrotatable in a second direction opposite the first direction.

The central positioning base is preferably movable in an X direction bya first motor, preferably a gear box motor, and a Y direction by asecond motor, preferably a direct drive motor. The central positioningbase preferably includes a follower tracing the tooth pattern of thesecured master key. When the central positioning base is securing thekey blank at the key cutting module, the second motor is preferablyprovided with a variable amount of power depending on a substantiallyinstantaneous height of the master key tooth pattern being traced. Morepreferably, when the follower rides along an uphill portion of themaster key tooth pattern, the power provided to the second motor isreduced, and when the follower rides along a downhill portion of themaster key tooth pattern, the power provided to the second motor isincreased.

The master key alignment module is preferably slidingly disposed on afirst rail in the Y direction, and the extraction module is preferablyslidingly disposed on a second rail in the Y direction.

In another embodiment, the invention is an automatic key duplicatingmachine having a master key clamping module adapted to receive andsecure a master key having a tooth pattern to be duplicated. A masterkey alignment module is movably disposed into and out of proximity withthe master key clamping module, the master key being aligned by thealignment module within the master key clamping module. A key cuttingmodule is provided including key blank cutter. A central positioningbase is automatically movable into and out of engagement with the masterkey alignment module and alternately automatically movable into and outof engagement with the key cutting module. The central positioning baseis adapted to move the master key alignment module into proximity withthe master key clamping module and adapted to secure a blank key to becut at the key cutting module in accordance with the tooth pattern of aclamped master key.

In another embodiment, the invention is an apparatus for automaticallydetermining a type of a master key for duplication having a key clampinto which the master key is inserted and secured, the key clamp havinga key receiving guideway, and at least one blade cross-section detectormovably disposed within the key clamp in a direction substantiallyperpendicular to the key receiving guideway and laterally engageablewith the blade of the inserted master key. The cross-section detectorhas a profile corresponding to a cross-sectional profile of a given typeof key. When the blade cross-section detector engages a key of the typecorresponding to the profile, the profile substantially engages theblade and the master key is determined to be of the given key type.

In another embodiment, the invention is an apparatus for automaticallyaligning a master key to be duplicated, having a key clamp into whichthe master key is inserted and secured, the key clamp having a keyreceiving guideway. An alignment base is provided movable into and outof proximity with the key receiving guideway. An alignment head ismounted on a reciprocating shaft substantially perpendicular to the keyreceiving guideway and spring-biased in a distal position away from thealignment base. The alignment head is engageable with the master key asthe master key is being inserted into the master key clamping modulewhen the master key alignment module is in proximity to the master keyclamping module. A master key shoulder detecting switch is disposed onthe alignment base. When the master key is fully inserted into the keyclamp, a shoulder of the master key abuts against the master keyshoulder detecting switch to indicate full insertion of the master key.

In another embodiment, the invention is a system for extracting a keyblank from a pre-selected plurality of key blanks for cutting into aduplicate of a master key. At least one magazine houses a plurality ofkey blanks. A base is movable into and out of proximity with themagazine, the base having a key blank securing groove and a key blankclamp on at least one side of the key blank securing groove adapted tosecure a key blank inserted into the key blank securing groove from themagazine. A key extraction module is provided engageable with themovable base substantially adjacent the key blank securing groove andmovable to the magazine by the movable base. The key extraction moduleincludes a reciprocatable push rod, disposable behind a lowermost keyblank housed in one of the magazines, adapted to push the lowermost keyblank out of the magazine.

The invention also includes a fully automated method of duplicating amaster key. A master key inserted into a guideway in a clamping base isaligned by pressing down on outward-facing teeth side of the insertedmaster key. Complete insertion of the master key into the guideway isdetected. A locking force is applied on the blade against the clampingbase in a direction substantially perpendicular to the axis of theblade. The master key is clamped while the master key is subject to thelocking force applying step. The type of master key that is clamped isidentified by determining a plurality of physical parameters of the key.A key blank to be cut is secured in a movable base having a follower.The follower of the movable base is pressed against the master key toothpattern while simultaneously pressing the secured blank against a keycutter such as a cutting wheel.

Preferably, a plurality of key blanks are provided in at least onemagazine, more preferably a plurality of magazines each housing adifferent type, model, or color of key blank. The physical parametersdetermined in said identifying step enable automatic selection andextraction of a key blank from a specific magazine. Preferably, one keyblank is extracted from the magazine by pushing on the lowermost keyblank in the magazine and guiding the lowermost key blank into a keyblank receiving groove. Preferably, the complete key insertion detectingstep further includes the step of detecting the abutment of a shoulderof the master key against an alignment base.

Preferably, the master key identifying step further includes the stepsof sensing a length of the inserted master key and detecting thecross-sectional profile of the blade of the inserted master key. Theprofile detecting step preferably further includes the step ofattempting to close at least one pair of sliding elements around theblade of the inserted master key, the sliding elements being providedwith the profile of a model/type of key. If the attempting step issuccessful and the sliding elements substantially close around theblade, the inserted master key is determined to be of the type havingthe profile of the sliding elements. A plurality of pairs of slidingelements are preferably provided, each pair being provided with adifferent profile corresponding to a different type of key.

Preferably, a vacuum source is provided substantially around the keyblank cutter that removes substantially all debris created duringcutting of a secured key blank. Additionally, a cut key cleaner isprovided such as a rotating cleaning wheel, and the vacuum source isprovided substantially around the cut key cleaner, and substantially alldebris created during the cleaning of a secured cut key blank isremoved. The key blank cutter is preferably rotated in a first directionwhile cutting the secured key blank, and the cut key cleaner ispreferably in a second direction opposite the first while applying thesecured cut key blank to the cut key cleaner.

The pressing step of the inventive method further includes the steps ofvarying the amount of power provided to a motor tasked with generatingtorque for the pressing step depending on a substantially instantaneousheight of the master key tooth pattern in contact with the follower.More specifically, the power is reduced when the follower rides along anuphill portion of the master key tooth pattern, and the power isincreased when the follower rides along a downhill portion of the masterkey tooth pattern.

In another embodiment, the invention is an automated method ofduplicating a master key, including the steps of: aligning a master keyinserted into a groove by pressing down on outward-facing side teeth ofthe inserted master key; detecting complete insertion of the master keyinto the groove; applying a locking force on the blade of the masterkey; clamping the master key thus aligned; extracting a key blank from aplurality of key blanks housed in at least one magazine; securing a keyblank to be cut in a movable base having a follower; and pressing thefollower of the movable base against the master key tooth pattern whilesimultaneously pressing the secured blank against a key blank cuttersuch as a cutting wheel.

In another embodiment, the invention is a method of duplicating a masterkey, including the steps of: aligning the master key within a clamp on afirst base; clamping the master key thus aligned; securing a key blankto be cut in a second base having a follower, the key blank and thefollower being fixed relative to each other; and engaging the followerof the second base with the master key tooth pattern whilesimultaneously engaging the secured blank with a key blank cutter.

In another embodiment, the invention is a fully automatic keyduplicating machine, having a master key clamping module adapted toreceive and secure a master key having a tooth pattern to be duplicated.A master key alignment module is provided movably disposed into and outof proximity with the master key clamping module, the master key beingaligned by the alignment module within the master key clamping module. Amaster key identification module is disposed in fixed relation to themaster key clamping module, and identifies a type of key secured in themaster key clamping module. A key cutting module is provided andincludes a key blank cutter such as a rotating cutting wheel. A centralpositioning base is automatically movable into and out of engagementwith the key cutting module and secures a key blank to be cut at the keycutting module in accordance with the tooth pattern of a clamped masterkey.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood from the following descriptionof preferred embodiments together with reference to the accompanyingdrawings, in which:

FIG. 1 is a schematic of a conventional manual key duplicating machine.

FIGS. 2A-B are schematics of a key duplicating machine in accordancewith the invention.

FIGS. 3A-B are schematic overviews of a fully automatic key duplicatingmachine in accordance with the invention.

FIGS. 4A-G are schematics of an automatic master key alignment system inaccordance with the invention.

FIGS. 4H-I are schematics of the key alignment system of FIGS. 4A-Gincluding a master key clamping module in accordance with the invention.

FIG. 5 is a top elevation view of a master key alignment module inaccordance with the invention.

FIG. 6A is a side elevation view of a typical key.

FIGS. 6B-D are exemplary cross sectional views of different types ofkeys taken at the sectional line in FIG. 6A.

FIGS. 7A-D are front, side, and top elevation schematic views,respectively, of an automatic key identification system in accordancewith the invention.

FIGS. 8A-B are front sectional schematic views of one pair of slidingelements opening and substantially closing around a key blade of thesame corresponding type as that of the sliding elements in accordancewith the invention.

FIG. 9 is a front sectional schematic view of the sliding elements ofFIG. 8 failing to close around a key blade of a different type notcorresponding to that of the sliding elements in accordance with theinvention.

FIG. 10 is an exploded perspective view of a key identification modulein accordance with the invention.

FIGS. 11A and B are perspective views of a key identification module inrelation to a key clamping module in accordance with the invention.

FIGS. 12A-C are right, left, and top elevation views of a key extractormodule in accordance with the invention.

FIG. 13A is a top perspective view of the key extractor module of FIG.12 removing a key blank from a magazine and guiding it into a key blanksecuring groove in accordance with the invention.

FIG. 13B is a top perspective view of a key blank secured in thesecuring groove of the central position base on its way to be cut inaccordance with the invention.

FIG. 14 is an exploded perspective view of the key cutting module withthe cutting wheel and brush removed for clarity.

FIG. 15 is an enlarged perspective view of a mechanism for removing afinished duplicate key in accordance with the invention.

FIGS. 16A and B are top perspective and top elevation views,respectively, of a central positioning base in accordance with theinvention. FIG. 16C is a corresponding side elevation view.

FIG. 17A is an exploded perspective view of a fully automatic keyduplicating machine in accordance with the invention.

FIG. 17B is an enlarged view of the detail identified in circle 17Bshown in FIG. 17A.

FIG. 18 is a lower perspective view of a key blank magazine inaccordance with the invention.

DETAILED DESCRIPTION

Although the invention will be described in connection with certainpreferred embodiments, it will be understood that the invention is notlimited to those particular embodiments. On the contrary, the inventionis intended to cover all alternatives, modifications, and equivalentarrangements as may be included within the spirit and scope of theinvention as defined by the appended claims.

Description of the invention will now be given with reference to FIGS.2-18. It should be understood that these figures are exemplary in natureand in no way serve to limit the scope of the invention, which isdefined by the claims appearing hereinbelow.

Key duplication requires the analysis of the master key to determinemodel and tooth pattern, and then the forming of corresponding teeth ona key blank. It is generally necessary to firmly hold the master key andkey blank. As shown in FIG. 1 and described above, existing keyduplication machines accomplish this task by fixing the master key andthe key blank with respect to each other, such that they are orientedand aligned in a fixed and specific manner. Once secured, the existingmachine performs one of the following duplicating procedures: (1) thekeys remain fixed relative to each other and are moved in unison acrossa fixed tracer and a fixed cutter, or (2) the keys remain fixed relativeto each other and fixed relative to the machine, and the tracer andcutter are moved in unison across the keys. In both cases, the keysremain fixed relative to each other, and the tracer and cutter remainfixed to each other.

It is generally found that the keys loading locations are relativelyclose to each other and are in the same general alignment. This islikely due to the fact that a human operator is required to load bothkeys into the machine, and it is more user-friendly and intuitive forthe operator if the loading locations are close to one another and havethe same alignment configurations.

Such a configuration proves difficult for automated processes. For afully automatic process, the inventors have discovered that it isdesirable to enable the consumer to insert a master key into a slot andhave the key duplicated from the insertion point with the head of thekey always projecting from the machine, in the same fashion as when theconsumer opens a door. Consumers become nervous when their personalproperty such as a key is fully withdrawn into a machine, not to be seenfor even a minute. Additionally, if a person inserts either anon-recognizable key or a foreign object into the insertion slot of theautomatic device and it is fully withdrawn inside, a significant problemmay arise in trying to eject the key/object, potentially causing damageto both the inserted key/object and the machine in itself.

One solution to this issue is depicted generally in FIGS. 2A-B. Here,master key A and key blank B are not fixed relative to each other, as inconventional systems. Rather, two basic units 10 and 20 are provided.Unit 10 includes a tracer or follower 12 and key blank clamp 14.Opposite unit 10 is provided unit 20, which includes master key clamp 22opposite follower 12 and cutter 24 opposite key blank clamp 14. Masterkey A and key cutter 24 of unit 20 are in a fixed position, while unit10 is movable in the X-Y direction. This configuration, compared withconventional key duplication, requires a re-orientation of key blank Band of cutter 24. In this embodiment, key blank B faces master key A andis loaded from the opposite direction than master key A. Cutter 24 isoriented with the angled edge facing master key A. Unit 10 has means formoving in the X direction indicated by the lateral arrow. Duringduplication, force is applied in the negative Y direction as indicatedby the downward vertical arrows. The tracer or follower 12 and key blankB translate across the original key A and cutter 24 to reproduce themaster key's tooth pattern on key blank B FIG. 2B shows the system inmid-operation with a portion of the profile already formed into keyblank B.

The invention is well suited for a fully automated key duplicationmachine, for at least the following reasons. First, it allows the masterkey to remain in a fixed position, thus preventing any intentional andunintentional movement by the human user which might cause misalignmenteither before the process starts or in mid-duplication. Second, itallows for a mechanically favorable situation in which the cutter andits components remain fixed. Also, it allows the key blank to be easilyloaded from the ‘back’ side. This may be inconvenient for a humanoperator in a conventional setting, but it is well-suited for anautomatic loading system which requires space to move and operate.Finally (but by no means exclusively), the orientation of the key blankis also well-suited for an automatic system loading from the back side.From the perspective of a rear-placed loading system, it allows for‘blade first’ loading.

One such rear-placed blade-first blank loading system is describedhereinbelow, first conceptually with respect to FIGS. 3A and 3B, thenwith more specific detail in the remaining FIGS. 4-18. FIG. 3 shows anoverall schematic of a fully automatic key duplicating machine 40. Thechief components are: master key alignment module 50; master keyclamping module 100; master key identification module 130; key blankextractor module 150; key cutting module 200; and central positioningbase 250. Central positioning base 250 is movable amongst several of theother modules and is capable of engaging two of the other modules forinteraction with fixed components of the system. Base 250 is powered byany conventional mechanism of moving an object in one or two dimensions,such as a pair of encoded motors (one for the X direction, one for the Ydirection) run by a computer, PLC, or a similar controlling device. Thepowered movement of base 250 is depicted by solid line arrows; whenother movable but not self-locomotive components move as a result ofengagement with base 250 (or via other means), such movement is depictedby dotted line arrows.

The initial step i of the inventive method is the moving of alignmentmodule 50 into position near clamping module 100 so that a master key Ainserted therein (at step 0) will be properly aligned. Alignment module50 properly aligns the inserted master key (in a manner such as theexemplary alignment method to be described below), and when alignment iscomplete, clamping module 100 secures master key A by clamping it. Oncethe master key is aligned and secured, master key identification module130 determines which type and model of key the master key is so that anappropriate key blank can be selected.

Next, central positioning base 250 disengages from alignment module 50and moves to engage key blank extraction module 150 at step ii. Beforebase 250 disengages from alignment module 50, base 250 moves alignmentmodule 50 out of the way of the secured master key inside clampingmodule 100 in step iii as shown in dotted lines. Alignment module ispreferably spring-biased to remain out of the way after centralpositioning base 250 disengages therefrom. Extraction module is movablealong one or more magazines 190 that house a plurality of key blanks.Central positioning base 250 moves extraction module 150 to theappropriate magazine 190 in step iv, and extraction module 150 removes akey blank therefrom and guides it into key blank clamp 270 of base 250for securement.

In step v, central positioning base 250 moves over to both key cuttingmodule 200 and master key clamping module 100, which is possible becausethe alignment module 50 was moved out of the way (either by spring forceor some other mechanism) in advance. The key blank disposed in blankclamp 270 is moved into engagement with the key cutting module 200 andis cut in accordance with the tooth pattern of master key A in clampingmodule 100. In the preferred embodiment, base 250 includes a follower290 which traces or follows along the tooth pattern of the master key asbase 250 is moved across key cutting module 200 and key clamping module100 in step vi (see FIG. 3B).

Alignment module 50 is described in more detail in FIGS. 4-5. Module 50includes a main base 52 on which reciprocating rod 54 is mounted. On thedistal end of rod 54 is mounted alignment head 56; rod 54 (and thus head56) are kept extended in a distal position (see FIGS. 4A-B, for example)by spring 58. Alignment head 56 preferably includes an angled or slopedleading surface 57 to accommodate insertion of a master key A intomaster key clamping module 100; as key A is inserted, the blade easilyrides along sloped leading surface 57 and preferably in a groove in theunderside of head 56 to move alongside alignment head 56 and to pushhead 56 upward slightly in the +Y direction. A master key shoulderdetecting switch 60 is provided on alignment head 52 closest to theouter wall or housing 400 of the device 40 (see FIGS. 4A-B, forexample). When a master key A is fully inserted (see FIG. 4D), the keyshoulder abuts shoulder detecting switch 60 to indicate to the systemthat the key is fully inserted and the alignment process can begin.

As best shown in FIG. 5, alignment module 50 is preferably movable alongrail 51 by operation of central positioning base 250. In the preferredembodiment, alignment module 50 includes an engagement hub receiver 55which is adapted to receive an engagement hub 260 disposed on centralpositioning base 250. Base 250 is preferably used to move alignmentmodule 50 out of the way of clamping module 100, and spring 53 ispreferably provided to keep alignment module 50 out of the way ofclamping module 100 when central positioning base 250 disengages itsengagement hub 260 from engagement hub receiver 55 (e.g., if the machine40 is jostled or bumped, it is possible for the alignment module to rolldown its rail 51 if it were riot restrained by spring 53).

A locking switch or lever 62 is provided on alignment base 52 engageablewith the proximal end of reciprocating rod 54 (see FIG. 5). Preferably,locking lever 62 is rotatably mounted on base 52. When engagement hub260 of central positioning base 250 fully and firmly engages hubreceiver 55, the edge of central positioning base 250 abuts againstlocking lever 62 to press it into locking engagement with shaft 54 togenerate a “locking force” against rod 54 which keeps alignment head 56fixed in its distal position. A strong spring 64 is preferably providedto transfer force and to prevent full surface-to-surface contact betweencentral positioning base 250 and alignment module 50, which over timemight result in damage to either component, owing to the centralpositioning base effectively bumping into alignment module 50 every timea key is made. Spring 64 provides a large compressive force to stiffenthe position of alignment head 56 yet allows for some flexibility orplay to accommodate variations in tooth height on master key A.

Operation of alignment module 50 is as follows. In FIG. 4A, alignmentmodule 50 begins distant from clamping module 100, preferably by passiveoperation of spring 53. When the customer begins the ordering process,central positioning base 250 and its engagement hub 260 are already inengagement with hub receiver 55. Before the customer inserts a key, base250 moves alignment module into position just opposite master keyclamping module 100 as shown in FIG. 4B. The customer is then instructedto insert her key into slot S, and does so in FIG. 4C. Key insertionbegins in the +X direction. Key length sensor 132 (part of master keyidentification module 130, to be described below) is pushed in the +Xdirection as key A is inserted against the biasing force of spring 134.Length sensor 132 measures the key length. Owing to the biasing force ofspring 58, alignment head 56 guides the blade of the key, confines keymovement, and loosely aligns the key blade by pushing it down in the −Ydirection into the clamp (to be described below).

Master key A is shown fully inserted in FIG. 4D, and key shoulder A1engages shoulder switch 60. When switch 60 is engaged, and if lengthsensor 132 determines master key A to be of an acceptable length,central positioning base 250 moves alignment module 50 down in the −Ydirection as shown in FIG. 4E. This causes force to be applied just infront of the shoulder A1 and under alignment head 56. The alignment head56 still has some play, owing to the resilience of spring 58. Next,central positioning base 250 moves slightly in the −X direction to causebase 250 to engage spring 64 and produce force on locking lever 62,thereby transferring force to rod 54 (and thus alignment head 56)causing extra force to be applied to key A (see FIG. 4F). This lockingforce provides final alignment to the master key.

At this point, after a complete alignment sequence, the key is clampedinto position, and central positioning base 250 returns module 50 to its“out” location and disengages from alignment module 50. Spring 53maintains module 50 away from clamping module 100 in the +Y direction,as shown in FIG. 4G.

Master key clamping module 100 is best shown in FIGS. 4H and I. Module100 includes a clamping base 102 having proximal and distal clampingjaws 104A, B. To ensure that the master key A does not become misalignedas it is being inserted while the tip of its blade passes betweenproximal clamping jaws 104A and distal clamping jaws 104B, guidewaypiece 110 is mounted therebetween. Guideway piece 110 preferablyincludes projections 112 and a central guideway 114 that receives theinserted key A. In between adjacent projections are providedidentification slot 116, for reasons which will become clear below.Guideway piece 110 is preferably mounted to only one of the two portionsof clamping base 102.

Once the alignment module is finished aligning the key as describedabove, the two portions of clamping base 102 move together to lock thekey in place. It is not necessary for both portions of base 102 to moveto clamp key A; one portion may be fixed, and the other portion may moveto meet it. \

Master key identification module 130 is depicted best in FIGS. 6-11. Oneportion of identification module 130 has already been described: keylength sensor 132 shown in FIG. 4. When master key A is fully inserted(as detected by shoulder switch 60), the length of the key is determinedby spring-biased length sensor 132. That is one piece of information,but it does not determine what type of key has been inserted. As shownin FIG. 6 the blade of master key A (FIG. 6A) can have one of severaldifferent cross-sectional profiles, as shown in FIGS. 6B-D; FIG. 6Bdepicts a first cross sectional profile A′, FIG. 6C depicts a secondcross-sectional profile A″, and FIG. 6D depicts a third cross-sectionalprofile A″′. Determining which profile a key has effectively determineswhat type of key it is.

FIG. 7 shows the other portion of master key identification module 130:sliding elements 140 that can slide to and away from the key (FIG. 7)through identification slots 116 provided in guideway piece 110 (seeFIGS. 4H-I). As depicted in FIG. 7, four pairs of slides 140-A-D areprovided. Each slide 140 has a profile 142 that corresponds or issimilar to the cross-sectional profile A′—A′″ of one side of a specificmodel of a key. Each identifiable model of key would have a pair ofslides 140 each with a corresponding profile for that side of the key,so that when the slides are closed completely together, they form a holein the shape of a keyhole for that particular type. Several pairs ofslides 140 may be provided in each system as to be able to identifyseveral types of key. Means are provided for identifying when each slideis in an open position, fully closed position, or past closed position;such means may include an optical switch or electronic contact switch.The slides are provided with means for moving back and forth, such as aspring, motor or solenoid. The preferable default position of the systemleaves the slides in the open position.

FIG. 10 shows a more detailed embodiment of the alignment system of theinvention. For clarity and simplicity, only the left-side elements areshown. Sliding elements 140A-C are respectively provided with profiles142A-C, which correspond to different types of keys. For example,profile 142A may correspond to a Schlage key, profile 142B maycorrespond to a Kwikset key, and profile 142C may correspond to a Weiserkey. Other key types may be identified with other correspondingprofiles. Sliding elements are provided with spring bias by springs144A-C, and are slidable into and out of housing 146. Proximal ends ofsliding elements are provided with optical sensor flags 148A-C.Positions of sensor flags are read by optical recognition printedcircuit board 147 through the window in isolation foil 145.

The operation of the slide elements is shown best in FIGS. 8, 9, and 11.Each slide element 140 is initially positioned away from key A and ismoved to close around the master key A. As shown in FIG. 9, if theprofile of the key does not correspond to the profile of slidingelements 140, and thus if contact is made between a sliding element 140and the key before the slide reaches its fully closed position, then theoptical switch will not be triggered for that slide. When a pair ofslides has at least one un-triggered switch then it may be concludedthat the sample key is not of the same type as the slider pair'sprofile. If premature contact is not made with the master key and theslide elements 140 closes substantially around the blade of the key,then the optical switch will be triggered for that slide. If bothswitches of a slider pair are triggered, then it can be concluded thatthe sample key cross-section is capable of fitting within thatslide-pairs outlined hole (see FIG. 8B).

FIG. 11A depicts a master key A clamped in clamping module 100 withsliding elements 140A-C in an open position. FIG. 11B depicts the sameclamped master key A with sliding elements 140A-C closing around thekey.

The slides are preferably made of a thin and strong material such ashardened steel. Such a thin material will allow several rows of slidersto be placed in one system.

There are cases in which a certain number of slide-pairs may be capableof identifying more key models than there are slide-pairs. For example,after studying the combinations of models in a particular system, it maybe concluded that a particular slide profile may substitute for multipleother slides. Further, in some cases, it may be possible to usedifferent combinations of ON-OFF switches of different slides todetermine models. Such configurations would reduce the amount of slidesin a system.

It is also important to note that a slide-pair may be designed in a waywhere they do not contact each other when in a closed position. Theswitches may be placed to determine position rather than determining aclosed or not-closed situation.

In an alternate embodiment, pins may be placed in strategic locationsinstead of slides to determine key types.

FIGS. 12 and 13 illustrate details of the key blank extraction module150. Module 150 includes an extraction base 152 on which is mountedmotor 154 (FIG. 12A). Motor 154 includes gear 155 which meshinglyengages rack gear 156 (FIG. 12B). Slider 158 is mechanically linked orattached to gear rack 156, and push rod 159 is attached or mechanicallylinked to slider 158. Operation of motor 154 therefore causes push rod159 to move. Extraction module 150 is disposed below and behind thelowermost key blank housed in a magazine 190 so that when motor 154causes push rod 159 to move, push rod 159 pushes the key blank B out ofmagazine 190 and into key blank clamp 270 of central positioning base250 (see FIGS. 13-A-B). A guide roller 170 is attached to base 152 viabracket 172; when a key blank is extracted from a magazine, the blade ofthe blank rides along guide roller 170. Guide roller 170 is preferablyprovided with a circumferential channel or groove 174 for ensuringproper guidance and alignment of the blank.

Proper alignment of the key blank is critical while the key blank isbeing extracted from the magazine and placed into blank clamp 270.However, because keys have relatively narrow blades which terminate in awider head, guiding and supporting the key while it is being extractedis made more complicated. In one embodiment, a key support arm 160having a blade support platform 162 is provided attached to theextractor base 152. In the preferred embodiment, blade support platform162 includes vertical guide walls 162A designed to keep the blade of thekey from experiencing roll, pitch, or yaw. However, the blade supportplatform 162 must be moved out of the way when the key head is ready topass therethrough, since the key head is wider than the space betweenguide walls 162A.

FIG. 12B best shows one embodiment of the mechanism for moving the keysupport arm 160 and blade support platform 162 out of the way of theoncoming key head. Key support arm 160 is pivotably attached to base 152at pin 161; arm 160 is biased upward by a spring (not shown). Slider 158is provided with a cam rider 157 which rides along the upper surface ofkey support arm 160. The upper surface of key support arm 160 includes aproximal raised camming surface 163, a central lowered camming surface165, and a distal raised camming surface 167. Ramped portions 164 and166 are provided on either side of the lowered central camming surface165 to smooth the transition between sections. When cam rider 157 ridesover either of the proximal or distal raised camming surfaces 163 and167, the cam rider 157 pushes the key support arm 160 down away from theemerging key blank to prevent contact between the emerging key blank Band the blade support platform 162. Only one motor 154 is required toextract the key blank and move the key support arm 160 into and out ofengagement with the key blank.

Extraction module 150 includes an engagement hub receiver 180 (FIG. 12C,FIG. 13B) for receiving engagement hub 262 on central positioning base250. Engagement module 150 is slidable along rail 175 (see FIG. 13A) asit is moved by central positioning base 250. Rail 175 preferably runsunderneath magazines 190 disposed in magazine rack 192. Once the centralpositioning base 250 has received and clamped a key blank, it disengagesfrom extraction module 150 as shown in FIG. 13B and moves over to keycutting module 200.

As shown in FIG. 18, the bottom of magazine 190 preferably includes apair of leaf springs 194, which serve several functions. First, leafsprings 194 help prevent the lowermost key blank from sliding out ofslot 196 without the aid of extraction module 150. Second, the pair ofleaf springs 194 are spaced apart so as to serve as a guideway for theblade of the key. As the key blank is pushed out, leaf springs 194 keepthe blade straight, until the head of the blank key passes over thesprings at which point the leaf springs are simply pushed downward bythe head of the key. Once the key is fully removed from the magazine,leaf springs 194 snap back into place to secure the next key.

Key cutting module 200 is best depicted in FIGS. 14 and 17B. A cuttingwheel housing 202 and a cleaning wheel housing 204 are provided,respectively mostly enclosing a cutting wheel 222 (FIG. 17B) and acleaning brush/wheel 224 (FIG. 17B). Housings 202 and 204 are connectedby a main vacuum housing 206 to a vacuum source 208. It is veryimportant to provide a way to remove the debris caused by the cuttingand cleaning processes, since there are a significant number of movingparts that can be compromised if metal shavings permeate the device.

Housings 202 and 204 do not completely surround the cutting and cleaningwheels 222 and 224 or they would be incapable of cutting and cleaning;windows 203 and 205 are provided respectively in housings 202 and 204.To maximize the focus of the negative pressure of the vacuum around thekey blank being operated upon without interfering with the cutting andcleaning processes (and thus to maximize the removal of debris),flexible flaps 210, 212, and 214 are provided surrounding windows 203and 205. Flaps 210, the distal flaps, are longer than the proximal flaps212. This allows central positioning base 250 to move into engagementwith the cutting and cleaning wheels and not inadvertently folding theflaps over the cleaning/cutting wheels. That is, the central positioningbase 250 first moves against the distal flaps 210 to push them out ofthe way while clearing proximal flaps 212. Then the central positioningbase 250 can get closer to the cutting/cleaning wheels and pushes theproximal flaps 212 out of the way.

In the preferred embodiment, cutting wheel 222 and cleaning wheel 224are disposed on the same rotating shaft 226, which is driven by drivebelt 230 attached to motor 232. Motor 232 is reversible and is reversedbefore the key blank is cleaned at the cleaning wheel; the rotatableshaft 226 is rotated first in one direction during cutting and then theother direction during cleaning, so as to cause the cleaning wheel 224to remove flashes and burrs from the trailing edge of the newly cutduplicate key. Burrs and debris generally hang from the trailing edge ofa newly cut key. By reversing the direction of motor 232 (and thus drivebelt 230 and cleaning wheel 224), the duplicate key need not be rotatedupside down or in any way removed from blank clamp 270 for extraneousmaterial to be removed from the trailing edge.

When the duplicate key is finished and ready to be removed from themachine 40, central positioning base 250 moves the key under removalbase 300 as shown in FIG. 15. Removal base 300 has a pin 302 whichprojects into the hole of finished duplicate key B′ when the key B′ isso positioned. Pin 302 engages the hole of key B′, blank clamp 270releases the securing force on key B′, and central positioning base 250moves away from base 300. Because pin 302 is projecting within the holeof key B′, the key slides out of blank clamp 270 and falls down adispensing chute or into a tray (not shown).

The prime mover of many of the aforementioned modules and functions ofthe invention is central positioning base 250, itself depicted in FIGS.16A-C. As indicated above, base 250 has two engagement hubs 260 and 262(see FIG. 16C) for engaging master key alignment module 50 and key blankextraction module 150, respectively, at their hub receivers 55 and 180.Base 250 also includes key blank clamp 270, having motor 272, keysensors 274 for detecting the presence of a key, and jaw 276 forsecuring a key blank B inserted therein. Follower tip 290 traces alongthe tooth pattern of the master key A secured in master key clampingmodule 100 while key blank B is being cut at key cutting wheel 222.

As best illustrated in FIG. 17A, central positioning base 250 ispreferably movable along two rails, an X-axis rail 264 and a Y-axis rail266. Preferably, two separate motors are provided for respectivemovement in the X direction and the Y direction. The X-direction motor(“X-motor”) is preferably a gear box motor, and the Y-direction motor(“Y-motor”) is preferably a direct drive motor. The Y-motor can be usednot only to move central positioning base 250 back and forth in the Ydirection but also at lower power to maintain a fixed position ofcentral positioning base 250 or to provide pressure to the key blankduring the cutting and cleaning steps of the operation. Indeed, duringthe cutting step, the Y-motor is provided with a variable amount ofpower depending on a substantially instantaneous height of the masterkey tooth pattern being traced so that internal play or flexion orfriction of the central positioning base 250 under significant pressuredoes not cause distortion of base 250 and thus misalign the key blankbeing machined and the follower 290 tracing the master key toothpattern. Preferably, when follower 290 rides along an uphill portion ofthe master key tooth pattern, the power provided to the Y-motor isreduced, and when the follower rides along a downhill portion of themaster key tooth pattern, the power provided to the Y-motor isincreased. In a preferred embodiment, Y-motor power while tracinguphills in the master key tooth profile is approximately 70% of Y-motorpower while tracing downhills in the master key tooth profile.

The invention is not limited to the above description. For example, thealignment and identification modules are preferably used to align andidentify the master key to be duplicated, however these modules couldalso be used to align and identify the key blank to be cut. Also, theexemplary embodiments shown above depict a central positioning basemovable amongst several modules in an X-Y plane, i.e., in twodimensions. However, it is also contemplated to ‘stack’ the variousmodules vertically and have the central positioning base move in avertical plane (a Y-Z plane, for example), or in three dimensionsinstead of two dimensions.

Additionally, several modules are described as fixed and others asmovable. However, in most cases, the reverse may be true, as long asthere is substantially similar relative movement among the modules. Forexample, the key blank extraction module is described and shown in thepreferred embodiment as being movable along a row of fixed magazines.However, it would also be within the scope of the invention to provide afixed extraction module and a movable bank of magazines, for example ona carousel, where the proper magazine is selectively movable intoengagement with the fixed extraction module. As another alternative, anymodule that is shown as being passively movable by the action of thecentral positioning base (e.g., the master key alignment module, the keyblank extraction module) may be provided with its own motor for its ownindependent locomotion.

Similarly, although in the preferred embodiment the key cutting wheeland key cleaning wheel are shown as being coaxial on a single shaft thatcan be rotated in both directions, it would also be within the scope ofthe invention to provide two separate rotating elements, one for the keycutter and one for the cut key cleaner. The invention is also notlimited to the use of either a key cutting wheel or a key cleaning wheelper abut may instead employ other devices for cutting the key blank andfor cleaning the cut key, either known now or to be developed in thefuture.

As another variation, the key identification module may include anoptical or electronic scanning device for detecting any of theparameters of the master key, including key length, bladecross-sectional profile, and/or tooth pattern.

Having described certain embodiments of the invention, it should beunderstood that the invention is not limited to the above description orthe attached exemplary drawings. Rather, the scope of the invention isdefined by the claims appearing hereinbelow and any equivalents thereofas would be appreciated by one of ordinary skill in the art.

While particular embodiments and applications of the present inventionhave been illustrated and described, it is to be understood that theinvention is not limited to the precise construction and compositionsdisclosed herein and that various modifications, changes, and variationsmay be apparent from the foregoing descriptions without departing fromthe spirit and scope of the invention as defined in the appended claims.

The invention claimed is:
 1. An automatic key duplicating machine, comprising: a master key identification module including at least one key blade cross-section detector with a plurality of sliding elements configured to slide in a thickness direction of the master key, the master key identification module being configured to determine a key type for a master key based at least on engagement of the plurality of sliding elements with at least one side of a blade profile of the master key; a key extraction module configured to retrieve a key blank of an identified key type; and a key cutting module configured to cut the key blank in accordance with a tooth pattern of the master key.
 2. The automatic key duplicating machine of claim 1, wherein the master key identification module further includes a blade length sensor configured to determine a length of the master key, wherein the key type for the master key is also determined based on the length.
 3. The automatic key duplicating machine of claim 1, further comprising: a master key clamping module configured to receive and secure the master key.
 4. The automatic key duplicating machine of claim 1, wherein the plurality of sliding elements include a plurality of sliding element pairs, each of the plurality of sliding element pairs having a profile corresponding to a different key type.
 5. A method of automatically duplicating a master key, comprising: moving a plurality of sliding elements in a thickness direction of the master key such that the elements engage with a blade of the master key; determining a key type for the master key based at least on engagement of the plurality of sliding elements with at least one side of a blade profile of the master key; retrieving a key blank of an identified key type; and cutting the key blank in accordance with a tooth pattern of the master key.
 6. The method of claim 5, further comprising: determining a length of the master key, wherein the key type for the master key is also determined based on the length.
 7. The method of claim 5, wherein the plurality of sliding elements include a plurality of sliding element pairs, each of the plurality of sliding element pairs having a profile corresponding to a different key type. 